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Retort packaging transforms food processing industry
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Sunday, 01 June, 2014, 08 : 00 AM [IST]
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Nandita Vijay, Bengaluru
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fiogf49gjkf0d Reduction of heating time by 30-50 per cent, improved food appearance, better nutrition and taste are the significant factors seen to drive the increased utilisation of retort packaging in India.
In fact, retort packaging material has revolutionised the food processing industry with the concept of ready-to-eat and heat-and-eat offerings.
Technology for retort pouch manufacturing is available from Council for Scientific & Industrial Research-Central Food Technology Research Institute (CSIR-CFTRI), Mysore. There are around six large companies, which successfully manufacture and market range of instant vegetables in retort pouches in domestic and export markets. CSIR-CFTRI has transferred the technology to many food processing companies.
“Retort flexible packing is positioned to capture the market conquered by cans, glass bottles and plastics,” states Prof. Ram Rajasekharan, director, CSIR-CFTRI, Mysore.
Pioneering tech
The entry of retort packaging has enhanced the acceptance of ready-to-serve meals not just in homes but for the armed forces located in the remote and inaccessible regions in the country. It was the Defence Food Research Laboratory and the CSIR-CFTRI which came in with packaging concepts. The technology was transferred to MTR Foods which is the pioneer for ready-to-eat south Indian menus.
In the area of scientific and technological achievements, DFRL, has catered to the needs of armed forces providing the technologies for the development of pack rations, preservation and packaging methods for long distance transportation of perishable products. DFRL has also developed the science for evaluation of nutritional requirements of troops deployed under different climatic conditions, quality assurance methods for pack rations, establishment of commercial sources of supply of the products developed in the laboratory. However all these products use the retort packaging.
Hub for tech transfer
As part of its business development initiatives, DFRL has been a hub for technology transfer. From retort processed foods many of the processes and technologies are suitable and adaptable to cottage scale or small-scale industry level operations.
Better taste
According to a report on retort flexible packaging, it is stated that leading global companies like Pyramid Group, CLP Packaging Solutions, Allied Flex Technologies and Amplas, view that the concept has transformed the food processing sector. This is because food packaged in retort pouches tasted better than canned ones.
“Moreover food packaged in a conventional can must be cooked twice as long as the food contained in the retort pouch. But retort packaging has a thin profile and smaller ratio of surface area to volume. Heat penetrates the food much faster and reaches the inside of the pack easily,” stated the report.
“Retort pouch processing technology has been widely recognised as one of the alternatives to metal cans for producing thermally processed shelf-stable foods. The retortable pouch is a flexible laminated pouch that can withstand thermal processing temperatures and combine the advantages of the metal can and plastic packages. Flexible retortable pouches are a unique alternative packaging method for sterile shelf- stable products. The retort pouch has many advantages over canned and frozen food packages for both the customers as well as food manufacturers. The advantages are pouch profile, storage and preparation efficiency, savings in transportation, package cost, improved flavour and savings of energy. Therefore, in a research effort to develop and evaluate the shelf-stable retort processed ready-to-drink (RTD) of traditional Thari Kanchi payasam in flexible retort pouches proved an attempt to highlight the stability and adaptability using retort pouch processing technique. The research also helped to evaluate the changes in quality attributes during storage, according to scientists from the Food Engineering and Packaging Division, Defence Food Research Laboratory, Mysore.
Commercial viability up
Development of retort pouch processed Thari Kanchi payasam has shown that traditional products have now increased the commercial viability of products. The microbiological analyses revealed that the product was ideal to be marketed as its contents remained sterile during the entire storage at ambient 27-30 degree centigrade and elevated conditions of 45 degree centigrade. Hence the product was safe for consumption. The changes in peroxide value and free fatty acid content during storage did not affect the acceptability of the product and was well within the limits. “In view of the acceptability of the product both in terms of physico-chemical and sensory properties, it could prove to be a means of value addition, product diversification and export promotion for traditional foods,” stated a scientist from the Food Engineering and Packaging Division, DFRL, Mysore.
Modernised concepts
In an age where consumers are looking for convenient Ready- to-Eat foods (RTE) enclosed in aluminium containers or pouches that only need to be cut and heated before being served, retort packaging has modernised concepts of serving. Another industry which is seen to have made significant in-roads in India is the instant vegetables-fruits in retort pouches. This finds application not only as home meal replacement in working dual income households but also in fast-food restaurants and multi cuisine food joints. These are handy meals for armed forces and paramilitary forces deployed in remote places. RTE food (all retort packaged) includes wide range of products like the vegetarian, non-vegetarian, conventional meals and desserts.
Cups & tubs - a paradigm shift in packaging
According to Chetan L Hanchate, CEO, Centre for Processed Foods, new trend in the packaging space are the retortable cups and tubs which come in with a peel layer that is seen as a paradigm shift. The concept of single consumption, easy to carry and convenient to consume besides being able to heat using a microwave caught the fancy of the Indian consumers. It is this which is generating the interest for food processing companies to go in for the retortable cups and tubs.
Specialty rigid packaging triumphs
The entry of specialty rigid packaging by global packaging major Printpack Packaging Supplies (India) Pvt. Ltd was a leap frog in terms of providing foolproof multilayer barrier containers, ensuring total hygiene and higher safety standards to the food processing industry.
The company is a subsidiary of the US-based Printpack. Specific for the Asian market, it offers the specialty rigid packaging. “Going by the significant opportunities in the food processing sector, the market is promising with a growing customer acceptance. This packaging is suitable for retort, hot fill, aseptic and MAP applications. “Broad range of products in categories such as Ready-to-Cook (RTC), RTE and Ready-to-Drink (RTD) can be provided in long shelf-life format,” informed Vivek A Chougule, MD, Printpack Packaging Supplies (India) Pvt Ltd.
“As consumer preferences are changing, demand for shelf-stable products is increasing in India. Indian consumers are rapidly adapting to convenient portion packs of hygienic, nutritious, branded and well packaged food products,” he added.
Awareness - key issue
The big challenge in India is to grab the first order from the food processing industries. “There is also the issue of awareness on the safety of the food product and this is where we teamed up with Centre for Processed Foods (CPF) to educate the industry on its advantages. In addition, we have also utilised our technical know-how and network of channel partners, to be associated closely with customers who include Double Horse, Manjilas,Crave Eatables,FineTune Foods and Rajamma Agro to commercialise broad range of products in RTC & RTE categories,” stated Chougule.
The multilayer barrier container packaging is now commercially used for Indian sweets and savouries like kheer, halwa, spreads, gulab jamun, rasgulla, rajbhog, sweet corn and an assortment of cooking pastes. Favourable response from consumers is evident through rapidly growing sales and feedback from delighted consumers. This advanced packaging format fulfills the consumer demand by offering long shelf life products assuring nutrition, hygiene and food safety at affordable price. Shelf appeal is achieved by using differentiated container design & shapes that showcase the product along with various decoration options. Additional consumer convenience is provided by easy peel lid, option of re-closable cap and folding spoon. These modern, portable packs are microwavable for quick heat- and-eat foods therefore offering ease for on-the-go or for at-home use.
The flexible and rigid packaging market of India is estimated at about US$24.6 billion with an estimated growth of CAGR 15% between 2013 and 2018.
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